[Mk2] [Turbo] ST205 Charge Cooler - what else do I need?

[toxo]

I would assume the throttle body support is required, Toyota will have put it there for a reason. It is the only thing holding the top of the inlet manifold + tb in place. Other than that the inlet manifold is supported with 2 braces underneath that run between 2 of the inlet runners and the block. So, the throttle body support is the only thing holding the top half of the inlet manifold in place. Your choice

In my pic above, the standard Rev3 MR2 parts are on top and the Celica equivalents are underneath. The bolts highlighted in red are the same on the Celica and the MR2.

If you're not going to put the Celica engine hanger on then you will have to take the MR2 one off. Then how will you get your engine out? Also the Celica one has an additional support for the core on it. Remember the core is HEAVY when it's filled with water, in terms of centre of gravity it's quite high up, and if you don't bolt it down somewhere all that will be holding it in place is the throttle sock and the silicon hose on the turbo.

Here's a pic of the 2 hangers together:

[toxo]

Jeff, in my parts list that you have pasted the first item is a bottle of ForLife coolant! You can use any old stuff in the chargecooler I'd imagine, but I had a load of ForLife lying around which is why I used it (plus it's what Toyota use in the core).

The little white tank you have is the CC Expansion Tank. And yes, you do have the throttlesock attached. There are always a few ST205s being broken on eBay, I'd suggest you ask around there.

[JeffD]

DOH! Silly me.

Ok - so am I right in thinking I just need those final 3 items then? ie.

78024-88480 Accelerator bracket £13.47
17871-88480 Throttle Body Support £31.17
12281-88480 Engine Hoist Hook £35.38

[toxo]

That's all you'll need from Toyota.

Unless you can find a supplier of 10M of 22MM I/D hose, you'll need to use 19MM I/D. Some people have managed to squeeze the 19MM I/D hose onto the pipes on the pump and core, which are 22MM O/D. I couldn't, so I used 22MM -> 19MM reducers. You'll also need some 32MM -> whatever hose size you use reducers for the radiator, as well as all the required hose joiners & jubilee clips to plumb the lot together. None of the GT4 hoses are any use.

Then you'll need to decide how you're going to do the electrics for the pump, and will require a 30A relay etc.

Then you can get going and make yourself some radiator mounting brackets

I'd recommend you refurb your pump prior to installation as it will have been running for at least the last 10 years. There's a guide available online somewhere. If you're not, I would at least start it up and make sure it runs with no noise. Also you can undo the 3 bolts on the inlet end and pop the top off and make sure there's no crap in there. Mine had some grit in it and wouldn't spin.

[JeffD]

Do you know the toyota part nos for the pump refurb so I can get them ordered? Trying to collect all the bits ready :-) ta!

[toxo]

You can't order the bearings from Toyota but they are a standard part you can get from eBay etc.

Goto http://www.gtfours.co.uk/ and click How to.. -> Repair/Maintain -> Overhaul IC Pump -> 205 (Can't link directly as site has Referrer checking)

This says you need "2 bearings - 1 x 609-ZZ and 1 x 629-2RS"

[JeffD]

Just ordered and paid for them both from a company on ebay - £5.35 delievered and thanks for link.

[Steve-O 2007]

Jeff please can you send a link of the Ebay auctions you used

Thanks

[JeffD]

Its a seller called "bearbrok"

Go into their shop then just type in the bearing numbers as given earlier in thread.

Just contacted the chap who sold me the chargecooler and hes going to let me have the remaiming the bits I need - result! :-)

[toxo]

That's nice of him Have you decided how you're going to control the pump yet? I just have mine on all the time...

[Steve-O 2007]

That's nice of him Have you decided how you're going to control the pump yet? I just have mine on all the time...

Seems the easiest way, Thats how I was going to do mine

[JeffD]

On all the time - thats why I wanted the bearings for refurb.

Are there any seals/bushes etc or anything to replace too or is that it?

[toxo]

Someone posted up somewhere about replacing the brushes as well but he didn't post up any more info other than that. I think you'll be fine though to be honest.

[JeffD]

BTW I tried to follow the link you put up to those L shaped reducers for the rad but couldnt find them on the site - can you post up a more specifuc link? cheers!

[toxo]

Oh have they changed their website again? I used these ones:

http://www.siliconhoses.com/content.asp ... &cat=0022R

They are expensive, and I used quite a few of them. However they're very robust and allow a fair bit of flexibility.

Luke reckons you can hammer the hell out of the 19mm pipe and one that's got it hot it will fit on the 22mm pipes.

[Driftlimits Performance]

Jeff you numpty I said I'd get you all the reducers and stuff. I have a good relationship with SFS Performance.

[mazmilly99]

how much hosing is needed? To the rad and back, 10-15m about right?

[toxo]

10m is about right. You end up with a little left over but not a great deal.

[toxo]

Jeff, my apologies but some of the part numbers on my thread were wrong These are the bolts you need 2 of for bolting the chargecooler core down onto the head:

T90119-08790

I've no idea where I got that other part number from but those bolts are neither from an MR2 or a Celica. They're also not long enough & the wrong thread pitch.

Oh and bolting the core down makes a massive difference, especially if your core has additional heat lagging on the underside. However you will only be able to bolt down in one location unless you have the Celica engine hanger which will leave the core a little lopsided (well it did on mine with the heat lagging anyway).